Lean Manufacturing Changeover Specialist

• Analyze current changeover processes and identify opportunities to reduce downtime and improve efficiency.
• Evaluate and prioritize the longest lead-time activities during changeovers.
• Develop standardized processes and procedures for changeover execution.
• Partner with team leaders to improve resource allocation and workforce utilization.
• Create and implement pre-changeover preparation strategies.
• Coach and train teams to manage changeovers with the same focus, urgency, planning, and accountability as production operations.
• Establish best practices for managing and clearing critical path activities.

• Partner with Food Safety and Quality (FSQ) teams to evaluate cleaning requirements and establish risk-based cleaning practices.
• Educate production teams on the purpose and requirements of cleaning procedures.
• Collaborate with operations teams to identify and eliminate overcleaning while maintaining quality and compliance standards.
• Develop and revise standard work and task flow processes to improve changeover speed without compromising safety, quality, or effectiveness.

• Conduct process mapping, value stream mapping, root cause analysis, 5 Whys, fishbone analysis, and other Lean methodologies to identify improvement opportunities.
• Learn and develop expertise in manufacturing equipment, cleaning practices, and operational processes.
• Identify operational pain points and evaluate opportunities to improve equipment design, processes, and cleaning methods.
• Design, execute, and evaluate controlled improvement experiments during changeovers.
• Investigate capital improvement opportunities and present recommendations to engineering teams.
• Implement sustainable process improvements and monitor results.

• Research best practices from other manufacturing facilities and industries.
• Evaluate innovative approaches to cleaning, maintenance, and operational efficiency.
• Apply external insights and creative problem-solving techniques to improve safety, effectiveness, and changeover performance.

• Utilize manufacturing, quality, maintenance, and safety management systems to support decision-making and performance tracking.
• Analyze operational data to identify trends, opportunities, and performance improvements.
• Promote effective use of standardized systems and processes across teams.

• Bachelor's degree in Engineering, Manufacturing, Operations, or a related technical field and a minimum of 5 years of manufacturing experience;

• High School Diploma/GED and a minimum of 10 years of related manufacturing experience.
• Experience leading continuous improvement initiatives in a manufacturing environment.
• Demonstrated knowledge and application of Lean Manufacturing methodologies, including process mapping, value stream mapping, root cause analysis, 5 Whys, and fishbone analysis.
• Proven ability to identify inefficiencies, develop solutions, and implement sustainable process improvements.
• Working knowledge of manufacturing systems related to asset management, inventory/storeroom management, quality management, ERP systems, and safety/environmental programs.
• Experience analyzing operational data and using insights to drive performance improvements.
• Demonstrated experience applying standardized systems, processes, and operational excellence principles.
• Strong verbal and written communication skills with the ability to effectively coach, influence, and collaborate across cross-functional teams.
• Experience developing standard work, process documentation, and operational procedures.
• Ability to partner with production, quality, food safety, maintenance, engineering, and leadership teams to achieve business objectives.
• Proven problem-solving and decision-making skills in a fast-paced manufacturing environment.
• Ability to work a flexible schedule to support production changeovers and operational needs.

• Lean Manufacturing certification or formal Continuous Improvement training.
• Bachelor's degree in Engineering or another technical discipline.
• Experience in food, beverage, consumer packaged goods (CPG), or other regulated manufacturing environments.
• Experience leading Kaizen events or operational excellence programs.
• Knowledge of food safety, quality assurance, sanitation, and changeover processes in a manufacturing setting.
• Experience evaluating capital improvement opportunities and supporting equipment optimization projects.
• Familiarity with manufacturing performance metrics, downtime reduction initiatives, and production efficiency programs.

Our promise is simple. DAHL has proven year after year that we are flexible, consistent and easy to work with, which is why our clients and consultants have stayed with us, and we've continued to grow throughout the years.

Our clients know they can depend on our efforts, as we hold their priorities in high regard. We genuinely care about each and every relationship and promise to work with the utmost of respect, integrity and high energy, as we continually strive to build long-term relationships.